Flexible film application for decorative coatings

ABSTRACT

A film application system having multiple foil application stations. Each foil application station has a support for an elongated plastic component (typically vinyl) having an input and an output side. A drive moves successive elongated components along a path through the application station from the input side to the output side as decorative foil is applied to a surface of the component. A properly positioned and oriented transfer head applies heat and pressure to the elongated film as the component moves through the application station. The disclosed system must accommodate different style and shape components corresponding to different style windows, doors, or sashes. A backing fixture that is configured to support a given configuration component is positioned to support the component as the component moves through the application station in a region of the transfer head.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional application of, and claims priority to,currently U.S. patent application Ser. No. 12/855,798 filed Aug. 13,2010, now U.S. Pat. No. 8,460,489, entitled FLEXIBLE FILM APPLICATIONFOR DECORATIVE COATINGS. The present application claims priority to theabove-identified Patent Application that is incorporated in its entiretyherein by reference for all purposes.

FIELD OF THE INVENTION

The present invention concerns decorative coatings for buildingcomponents.

BACKGROUND ART

Components that make a window frame or sash are typically formed bymiter cutting extruded components to size before heating the miteredends and then pressing the heated ends together so that the melted endsbond to each other to form a four sided sash or frame. Further assemblyof the window may involve installing an insulating glass “IG” unit intothe sash or frame and possibly painting of the plastic that forms thesash or frame. Painting at this stage can be expensive and unnecessarilyincrease the cost and delivery time of the window or door to theconsumer. Decorative patterns can be applied to the window frame or sashprior to cutting of the component into pieces for assembly. Thesedecorative patterns could either be a solid color or could simulate awood grain finish.

One prior art machine, sold by CPS Resources of Indian Trail, N.C.28079, routes substrates such as picture frames past a flexible foil orfilm dispensing head. The speed of movement of the substrate matches theunwinding speed of the foil as the foil is brought into contact with thesubstrate. A combination of heat and pressure treatment of the foil asit contacts the substrate causes the foil to permanently adhere to thesubstrate. The present invention relates to improvements to this processespecially as the process relates to application of decorative film orfoil to window or door components that have variable profile shapes

SUMMARY

This disclosure relates to apparatus and method for applying adecorative material to specified surfaces of a component. In oneapplication, subsequent to the application of the decorative material,the component is cut and assembled to form a window or door frame orsash. In one embodiment, multiple decorative film application stationsare staged to apply a decorative foil to different surfaces of thecomponent.

A controller in communication with each of the multiple decorative foilapplication stations executes a control program for coordinating feedingof the component from one station to a next subsequent station. Thecontrol program executed by the controller also changes and controls aset up of each of the multiple stations for the profile to receive thedecorative material by means of an intuitive user interface.

In an exemplary embodiment, each foil application station has a supportfor the component (typically a vinyl lineal of a certain length) havingan input and an output side. A drive moves successive elongatedcomponents along a path through the application station from the inputside to the output side as a transfer foil is applied to a surface ofthe component. A properly positioned and oriented transfer head appliesheat and pressure to the transfer foil as the component moves throughthe application station. The disclosed system accommodates differentstyle and shape components corresponding to different style windowsframes, sashes, or door frames. A backing fixture is configured tosupport a given component profile, which is positioned to support thecomponent as the component moves through the application station in aregion of the transfer head.

In the exemplary embodiment, a controller presents to a user on acomputer monitor a menu of different components having differentprofiles for transfer foil treatment. The user chooses a particularcomponent from the menu and the controller identifies a proper recipefor use at each of the multiple work stations.

The recipe includes one or more of the following treatment parameters: aproper choice for the heat and pressure roller at each applicationstation, a proper backing fixture for the component as the componentmoves through an application station, an angle of approach for contactbetween the component and the a transfer head, a radial position of thetransfer head with respect to an application surface of the componentduring movement of the component through an application station, atarget speed of movement of the component through the applicationstation, a target temperature for the roller, and a foil width forapplication at each of the multiple application stations. In theexemplary embodiment, the user selects and installs the roller andbacking fixture and foil at each station and the controller throughmeans of communication with each station performs automated controland/or monitoring of the other parameters.

These and other advantages and features of the invention will becomebetter understood by reference to the accompanying more detaileddescription, which is described in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are perspective depictions of a foil application systemconstructed in accordance with an exemplary embodiment of the invention;

FIG. 3 is a perspective view of two abutting window parts that have beencut from a lineal and heat fused to form a window frame or sash;

FIG. 3 a is an end view of a component showing different surfaces to betreated by a transfer foil;

FIG. 4 is a perspective view of a single workstation for applyingflexible foil to an elongated component;

FIG. 5 is an enlarged side view of the workstation of FIG. 4;

FIGS. 6 and 7 are enlarged end views of the two successive workstationsfor sequential treatment of elongated window parts;

FIGS. 8-10 are perspective views of a single workstation shown a tape orfoil application zone or region in greater detail;

FIG. 9A is an enlarged perspective view of the foil application regionof FIG. 9;

FIGS. 11 a and 11 b are schematic depictions showing alternate backingfixtures for use with different configuration profiles of the elongatedwindow or door components; and

FIG. 12 is a schematic block diagram of a control system for controllingthe exemplary decorative tape application system.

EXEMPLARY EMBODIMENT

The drawings depict an application system 10 for applying a transferfoil or film coating to selected surfaces of a workpiece. In oneexemplary embodiment, the workpiece is a lineal 20 which is cut and thatused to construct a window or door frame or sash. The system 10 appliesa transfer foil F to multiple surfaces 22-25 (See FIGS. 3 a) of theelongated component which is then cut and assembled into a window ordoor such as the window frame W shown in FIG. 3. Such components arereferred to herein as lineals.

One Exemplary system 10 includes multiple decorative transfer foilapplication stations or work stations wherein each station applies adecorative transfer foil to different surfaces or regions of the lineal.In FIGS. 1 and 2, two such stations 12 a, 12 b are depicted. Generally,each station applies a transfer foil F to a specified exposed region ofthe elongated component so that each next subsequent station in a seriesof such stations covers a different exposed region until a desiredportion of the lineal has been covered with the foil F. Turning to FIG.3 a, for example, the surfaces 22-25, of the component 20 are coveredwith foil F in one pass of the component or lineal through fourdifferent foil applying workstations. An untreated lineal enters thefirst work station and all desired surfaces have been covered when thecomponent leaves the last work station.

The multiple work stations operate under control of a control station14. A programmable controller 300 (FIG. 12) at the control station 14communicates with each of the work stations to control treatment of thelineal as it moves through the multiple work stations. An executablecontrol program that runs at the control station 14 manages set up ofthe work stations to accommodate application of a specified width foilto different surfaces of a lineal having a specified profile at thedifferent work stations. As discussed in more detail below, appropriateset up at each work station involves controlled movement of a transferhead 60 of the work station before the work station can accommodate aparticular profile of lineal 20. As used throughout, the term “profile”means the cross sectional shape of the lineal 20 such as the shape ofthe end view of FIG. 3 a. It should be appreciated by one skilled in theart that although only one profile is shown in FIG. 3 a, a large numberof different profiles may receive decorative foils on specified surfacesand indeed the flexibility to rapidly set up the system to accommodate arange of different profiles in one advantage of the exemplary system.

A single foil application work station 12 a is shown in FIG. 4 and isseen to include a support or stand 40 having an input side 42 and anoutput side 44. A drive 50 which in one exemplary embodiment is anelectric motor moves successive lineals 20 (FIG. 2) along a generallylinear path through the work station 12 a from the input side to theoutput side as a thin layer of transfer foil F is applied to a surfaceof the lineal. A transfer head 60 includes a rotatably mounted driveroll 62 (FIG. 5) coupled to the drive 50. In addition to moving theelongated component, the drive roll 62 applies heat and pressure to thetransfer foil F as the lineal 20 moves through the foil applicationstation 12 a from the input side 42 to the output side 44. Motive forcefor moving the component is applied by the roll 62 but the roll does notdirectly contact the component due to the presence of the transfer foilF between the drive roll and the lineal.

The exemplary foil material is an elongated multi-layer plastic filmwherein one layer of the multilayer material is the decorative layer anda second layer is a backing layer B that is recoiled after applicationof the decorative layer to the lineal 20. Additional formulations of thefoil include a cover layer and possibly a separate adhesive layer forfixing the decorative layer to the lineal 20. In a typical operationapplication of heat and pressure with the foil F in contact with thelineal causes the decorative layer to bond to the lineal and the backingmaterial separates from the cover layer (if present) and is wound abouta takeup roll. Suitable foils F for use with the exemplary embodiment ofthe invention are commercially available from CPS Resources of IndianTrail, N.C. 28079.

Lineals are extruded with a variety of different cross sectional shapesor profiles. Each of the multiple work stations e.g. 12 a and 12 butilizes a backing or support fixture that is specifically designed tosupport the profile of a specific lineal as the lineal moves through thework station past the transfer head 60 and its drive roll 62. A typicallineal 20 can be over 20 feet in length and multiple pieces are cut fromsuch a lineal after the material or foil F is applied. A spacing betweensuccessive drive rolls 62 at two adjacent, successive workstations isless than the length of the lineal. Therefore, before the trailing edgeof a lineal moves out of driving engagement with one roll 62 (at a firstworkstation for example) it's leading edge passes or drivingly engages adownstream roll 62 at a next subsequent foil application workstation. Atransmission between an output of the drive 50 and the roll 62 includesa slip clutch. Use of such a clutch allows the motors of the two (ormore) drives to rotate at slightly different speeds so that the fastestmotor determines speed of movement of the lineal.

The transfer head 60 applies film from different angles with respect toa center axis of component movement through each station. The controlstation 14 includes a touch sensitive input screen 15 that transmitssignals to the programmable controller 300 and allows a user or operatorto choose a component profile from a menu of such profiles (See FIG.12). Examples of the head 60 (and its associated roller 62) approachingthe lineal 20 from different angles is illustrated by reference to FIG.3 a. A surface 22 of the elongated component is covered at a first ofmultiple successive stations using roll 62 a (See FIG. 3 a) having abeveled outer surface 63. If the surface 22 is generally parallel to afloor on which the workstation stand 40 rests, the angular spacing oroffset of a centerline 64 to the vertical (x axis in FIG. 3 a) is lessthan 15 degrees. The beveled surface 63 of the drive roll 62 a contactsa generally flat surface 22 (with of course the foil F interposed therebetween).

A similarly configured roll 62 b is used (at a later applicationstation) to treat the surface 23 which is seen to be oriented at a rightangle with respect to the surface 22. An angle θ₁ between the centerline64 of the roll is ninety degrees. Two other different configurationrollers 62 c, 62 d for treating the surfaces 24, 25 are depicted in FIG.3 a and these rollers 62 c, 62 d would be positioned at two additionaldownstream stations in the system 10. During set up of system, the userchooses an appropriate drive roll from an inventory of such rolls. Thedrive roll is keyed and mounts to a correspondingly keyed shaft. Theshaft also supports two collars (not shown) which limit side to sidemovement of the drive roll along the length of the shaft after theroller is properly positioned on the shaft.

In describing the operation of the various components of the foilapplication stations (e.g. 12 a and 12 b), it is useful to define aco-ordinate system such as the co-ordinate system shown in FIG. 1. Adistance along the path of travel of the elongated component is adistance along the z direction from an origin of the co-ordinate systemwhere the component enters the first workstation 12 a. A distance in aradial direction from the z axis of this system is designated as adistance R. Finally, the angular position of a location with respect tothe a vertical (perpendicular to the floor the stand 40 rests upon) isreferred to by an angle theta θ.

Controlling the Angle of Tape Application

In one exemplary embodiment, a dispensing roll 70 and a take-up roll 72are mounted to first and second rotatably mounted rings 74 a, 74 b. Thedispensing roll 70 is mounted to a ring 74 a on the input side 42 of theworkstation and the take up roll is mounted to a ring 74 b on thedownstream or exit side 44 of the workstation. The transfer head 50(including its pressure backing roll 62) is mounted to a cross piece 78that extends between two larger support rings 76 a, 76 b rotatablysupported by the stand at an input and an output of the workstation (SeeFIG. 4). The rings 76 a, 76 b are mounted to the stand 40 by means forfour spaced apart cam followers 80 (See FIG. 10). A drive motor 82supported by the stand 40 rotates the rings 76 a, 76 b (under control ofthe controller 300) to orient the transfer head 76 with respect to thepath of travel the lineal follows along the z axis. As an example, thehead 60 has been oriented at two different orientations spaced by anangle θ₂ at two successive work stations in the end view of FIGS. 6 and7. The presently preferred drive 82 is an a.c electric motor having anoutput shaft that rotates a drive belt (not shown), which engages acircumferencially extending gear 84 connected to the ring 76 a. Use of aservo drive motor is a possible alternate for use with the disclosedsystem for controllably rotating the rings 76 a, 76 b. Due to the rigidcoupling together of the rings 76 a, 76 b by the cross piece 78 therings 76 a, 76 b rotate together whenever the motor 82 is energized.

During set up of the application system 10, the controller instructs theoperator regarding relative positioning of the smaller, inner rings 74a, 74 b relative to the outer support rings 76 a, 76 b. In manyapplications, the rings 74 a, 74 b are oriented so that the foil unwindsfrom the supply, passes into engagement with the roller 62 and thebacking is rewound all within the same plane as the roller 62 with noangular offset. Other set ups for different component profiles requirerelative angular offset of one or both of the supply 70 and take up 72rolls with respect to the head 60 and its drive roller 62. This angularoffset of the coil and roll can be up to 45 degrees. As a specificexample, the transfer head is oriented directly above the lineal passingthrough the work station and both the ring 74 a on the input sidesupporting the dispensing roll and the ring 74 b on the output sidesupport the take up roll are rotated in a counterclockwise sense as seenin FIG. 4 by an angle of 30 degrees.

To re-orient (if needed) the rings 74 a, 74 b (and attached rolls) withrespect to their support rings 76 a, 76 b the user releases a brake 85comprising a plate carried by the ring 76 a (for example) by loosening alever arm 86 which lessens the frictional contact between the brake andthe ring 74 a (for example). The inner rings 74 a, 74 b are mounted totheir respective outer rings 76 a, 76 b by bearings which allow relativerotation of the ring 74 a (for example) with respect to the ring 76 a.Once an appropriate angular offset is set by the user rotating the ring74 a for example, the user retightens the brake 85. Note, in oneorientation wherein the rolls and drive roller are essentially co-planer(most common) a pin slips into aligned holes on the rings 76 a, 74 a(not shown) to supplement the action of the brake 85 In all situations,the rings 74 a, 74 b are fixed to their respective support rings 76 a,76 b when the motor 82 is actuated to rotate the head 60. In oneexemplary embodiment, the system 10 has a automatic brake 90 supportedby the stand 40 for stopping the rotation of the ring 76 in response tothe controller 300 to lock the rings 76 a, 76 b in relation to thestand. ve to each other once they have been properly oriented during setup of the system. The exemplary brake 90 is a commercially availablebrake having a pneumatically actuated brake shoe and is sold byTalamatic.

Radial In and Out Movement of the Transfer Head

The transfer head 60 is mounted to a generally planar support plate 110(FIG. 5) for radial movement in and out with respect to the z axis. Theplate 110 is coupled to four linear shafts 112 which pass throughbearings supported by a generally plate 120 supported by the cross piece78 a fixed distance from the z axis or path of lineal travel. In and outradial movement of the transfer head is achieved by changing aseparation of the two plates 110, 120 indicated by the arrow 121 in FIG.5.

Mounted to the radially fixed plate 120 is a mechanical jack screw 122having a shaft that connects to the support plate 110. An electric motor124 has an output coupled by means of a coupling to the jack screw 122for relative radial movement of the support plate 110 with respect tothe radially fixed plate 120. The distance separation between the twoplates 110, 120 varies depending on the profile of the lineal 20. Thecontroller 300 is programmed with the correct distance or separation foreach of the transfer heads of the multiple workstations so that for agiven lineal 20 the setup of this spacing is accomplished in anautomated fashion by sending appropriate energization signals to thevarious motors for controlled radial position of the head 60.

Side to Side Movement of the Transfer Head

The drive roll 62 is mounted for rotation about an axis 126 (See FIG. 8)transverse to the z axis and which changes depending on what surface ofthe lineal is to be treated with foil. In some applications it isnecessary to move the tangential position of the roll 62. This need isillustrated in the schematic depiction of FIG. 3 b which shows a linealsuistaable for fabrication into a double hung window frame supportingtwo sashes in gaps or channels 127 a, 127 b. Consider the two pressurerolls 62 a, 62 c depicted in FIG. 3 b. The first roll 62 a presses thefoil F against a generally planar surface 22 of the lineal 20 and has abeveled outer surface for pressing the foil against that surface. Nowconsider the roll 62 c. This roll (supported at a different work stationfrom the roll 62 a) also has a beveled surface for pressing the foilagainst a conforming surface 24 of the lineal 20. An axis of rotationfor the two rollers 62 a, 62 c are similarly oriented as determined bythe angular rotation of the head about the z axis. The plane in whichthe two rollers 62 a, 62 c rotate, however, is offset by distance deltaΔ₁. This offset is achieved by moving one of the rolls 62 c, 62 d withrespect to a nominal position for the roller. In a similar way, it isseen that the plane of rotation of the two rollers 62 b, 62 d are offsetby a distance Δ₂. (Note, these two rollers also indicate the need for andifferent angular offset of the transfer head for different treatmentsurfaces)

To achieve such side shifting of the roll, the plate 110 includes twoside by side linear rails or bearings 128 that support an insulatingplate 130 supported by those bearings (See FIG. 5). The plate 130 movesin a linear path with respect to the plate 110. As seen in FIGS. 8 and9, a housing or oven 132 partially encloses the roller 62. A flange 134supports a bearing 136, which supports a roller drive shaft 138 forrotation. During set up of a workstation an appropriately configuredroller 62 (in a preferred embodiment constructed from silicone) for aparticular lineal having a particular profile is attached to the rollerdrive shaft 138. A motor mounting plate 140 is coupled to the plate 130and supports the drive motor 50. An output shaft (not shown) of themotor is coupled by means of a drive belt to a gear 142 attached to theroller drive shaft, as shown in FIG. 9.

In the present example, side shifting of the oven 132, roller 62 anddrive 50 is achieved by a user rotating a manual crank 150. Rotation ofthe crank in one sense moves the roller 62 in one direction and rotationin an opposite sense moves the roller in an opposite direction. In theexemplary embodiment the hand crank 150 is coupled to a ball screw drivehaving acme threads. In an alternate example embodiment, side shiftingis achieved by a motor/servo drive directed by the controller 300.

Backing Fixtures

The enlarged depictions of FIGS. 8, 9, 9A, and 10 illustrate a foiltransfer zone or region 200. The foil F and the elongated component orlineal 20 enter this zone and come in contact with each other as theroll 62 applies pressure and heat to transfer a decorative layer of thefoil F to a surface of the lineal 20. Before making contact with thefoil F in the transfer zone, the lineal 20 is supported by a series ofparallel, generally horizontal entrance rolls 202. After transfer of thedecorative layer to an appropriate surface of the lineal 20, the linealis supported by a series of parallel, generally horizontal exit rolls204. In between these rolls, in a region of transfer each workstationincludes a specially configured backing fixture.

The exemplary system 10 can accommodate many different configurationlineal profiles. FIGS. 11A and 11B depict two end views of lineals 20 a,20 b having different shapes. In addition to requiring differentconfiguration rolls 62, the variety of different shaped lineals must beadequately supported and guided in the transfer region 200 as foil ispressed against a surface of the lineal to be treated. FIGS. 11A and 11Bdepict two different backing fixtures 210, 230 that support and guidethe lineals 20 a, 20 b. Note, each of the multiple stations 12 a, 12 betc through which the lineal moves has its own backing fixture, whichare not necessarily the same from one work station to the next.

A first backing fixture 210 (FIG. 11A) includes a stepped backing roll212 having two different diameter outer lineal support surfaces 213 a,213 b. The stepped roll 212 is coupled to an axle 214 having a length tofit in and be rotatably supported by trunnion bearings 220 (FIG. 8)mounted to the stand 40 on opposite sides of the transfer region or zone200. During set up of the workstation, the controller 300 displays tothe user a number (perhaps hundreds) of lineals by a designation andthen prompts a user to select from an inventory of backing fixtures androllers 62 so that an appropriate combination of roller and backingfixture is used at each work station 12 a, 12 b etc. In an instance inwhich the fixture 210 of FIG. 11A is appropriate, the user fits the axle214 into the bearings 220 so that the desired lineal of the manypossible profiles can pass through the zone 200 in contact with thebacking fixture in a manner depicted in FIG. 11A.

The backing fixture 230 is specially configured for a lineal 20 b havinga flat surface 26 spaced away from the roller 62. The lineal 20 b entersthe zone 200 supported by the entrance rolls 202 and passes through thebacking fixture 230 and in particular passes over two flat supportsurfaces 242 of the fixture that define a spacing to appropriatelyposition a top of the lineal for contact with the pressure roller 62. Afirst pair of sidewall guide rollers 232 engage one side wall S1 of thelineal and an opposite pair of side guide rollers 233 engage an oppositeside wall S2 of the lineal. An additional guide roller 234 engages asurface of the lineal from one side. The side to side spacing of therollers 232, 233 is adjustable so that the fixture can accommodatedifferent width lineals. The angle of an arm 238 that supports theroller 234 is also adjustable to contact the lineal at different angles.

During set up, the fixture 230 is placed by an operator into arectangular gap or space between the entrance and exit rollers 202, 204.Four guides 241 fit down into this gap so that four downwardly facingsurfaces 240 of the fixture abut a perimetrically extending rectangularborder or ledge 243 that surrounds the rectangular gap and which isdefined by the stand 40. (See FIG. 4) The position along the z axis ofthe fixture is determined by two notches 244 formed in the guides thathave a width that fits over the trunnion bearings 220 on opposite sidesof the lineal path of travel. No special tools are need for either ofthe fixtures 210, 230. The user lifts an existing fixture out of theway, obtains an appropriate next fixture from a stock or inventory ofsuch fixtures and slips it into place by placing a support axle 214 intothe trunion 220 or slipping the fixture into a position defined by thenotch 244.

Foil Guides

As depicted most clearly in FIGS. 8 and 9, the foil F is routed from thesupply roll 70 to the takeup roll 72 and through the transfer zone byelongated guide shafts 250, 252 properly angled and positioned withrespect to the roller 62. Before the roller 62 is moved radially intocontact with the foil, these shafts 250, 252 guide the foil F in a paththrough the transfer zone. An entrance guide shaft 250 is positioned todivert the foil F in its path from the supply roll and route the backingB to the second or exit guide shaft 252. During set up of theworkstation, a user or operator positions the guide shafts by properpositioning of three clamps 254, 256, 258 that are supported by anappropriate one of the two rings 74 a, 74 b. Proper set up results inthe foil passing along a path that is generally parallel to the surfacewhich the decorative layer of the foil F is designed to treat once thelineal is pushed into the transfer zone. As the lineal 20 approaches thetransfer zone, the motor 124 is actuated to bring the roller intoengagement with the foil. Once the foil is trapped between the roller 62and the lineal the frictional engagement causes the foil to unwind fromthe supply. As the lineal moves through the transfers region, the takeup roll 72 is rotated by a motor 260 coupled to a spindle 262 thatsupports the takeup roll. The spindle 262 supports an elongated clamp263 extending along its length to allow an end of the backing layer B tobe secured to the shaft or spindle 262 and hand wound a sufficientamount to connect the foil to the take up roll. When not being rotatedby the motor 260 a spring tensioner 264 maintains tension in the backingmaterial.

Sensors

A controller 300 (FIG. 12) at the control station 14 monitors a numberof different sensor inputs and controls a status of a number ofdifferent motors during operation of the system 10. Multiple opticalsensors 302, 304, 306 are mounted to a fence 310 for monitoring apresence or absence of a lineal at the transfer zone. Other sensorsmonitor the temperature of a heater supported within the oven 132 andthe temperature of the roll 62. During startup of the treatment of asuccession of multiple lineals, a user or operator inserts a firstlineal into a first workstation such as the station 12 a. Theappropriate position of the lineal is clear to the user due to thepresence of a fixture having a gap to accept the lineal. No motive forceis applied to the lineal until the head is moved into engagement withthe lineal. The first two sensors or switches 302, 304 signal thecontroller when the lineal moves into the transfer zone 200. The sensorsor switches 302,304 are located on the infeed side of the station andthe switch 306 is on the exit side. One switch 302 causes the controllerto bring in a horizontal roller clamp 308 into contact with the linealprior to the lineal entering the heated roller zone. A second switch 304brings the heated roller down to make contact with the lineal. Once thelineal moves forward through the transfer zone, its presence will tripthe third switch 306 which will bring in a second horizontal rollerclamp 309 into contact with the side of the lineal to keep its movementstable as it exits the machine. Once the trailing end of the profilepasses the switch 302 and the second switch 304 the 1^(st) clamp and theheated roller will retract. When the trailing end passes the thirdswitch 306, the roller clamp 309 is retracted. The horizontal clamps308, 309 are only used when there are no custom backing fixtures inplace at the station.

Successive lineals are maintained in abutting relation as they areplaced in succession into the first workstation 12 a. Retraction of thehead that rotates the roller 62 occurs when it is determined that atrailing edge of the lineal has passes a third sensor 306 and no linealis sensed by the sensor 302.

The oven has resistance heaters mounted in its walls that when energizedwith appropriate voltages reach a temperature of up to 1100 degrees F.These heating element^(s) radiate heat toward the roller 62 and moreparticularly cause the roller to reach a temperature of from 450 to 600degrees F. Thermocouple sensors inside the oven monitor the temperatureof the heating elements. An IR sensor 320 mounted to the outside of theoven monitors the temperature of the roller 62 to maintain the roller ata set point temperature or temperature range and further to preventdamage to the roller due to overheating. The controller 300 modulatesactivation of the heating elements to cause the sensed temperature ofthe roller to be maintained at or near a target temperature. The heatingelements supported within the oven are commercially available heatingelements obtained from Watlow Electric of St. Louis, Mo. In oneembodiment, the system 10 includes a width monitoring ultrasonic sensorcommercially available from Banner as part number S18UUARQ to warn auser when the foil F is not an appropriate width for the lineal surfacebeing treated or covered.

In the illustrated system a window or door lineal is typically extrudedvinyl and may includes a center or middle channel/track used to supporta window sash or door assembly. However, the component or lineal as nowdefined and used throughout both the specification and claims, alsoincludes any size or shape window, door, or part forming the window,door, or supporting track assembly, including but not limited to,stiles, rails, tracks, frames, jambs, headers, sills, and channels onboth interior and exterior sides of the window or door without departingfrom the spirit and scope of the claimed disclosure. In addition, thematerial composition forming the component is not limited to vinyl, butcould be any type of material, including without limitation, metal,plastic, fiberglass, polymeric composition, or naturally existingmaterial. Further the surface of the component could be cleaned ortreated, for example with a sealant or painted prior to use by anapplicator assembly constructed in any of the example embodiments of thepresent disclosure. It is within the spirit of the present claimeddisclosure that the numerous uses of the term “component or lineal”,whether in singular or plural form throughout the various exampleembodiments, of applicator assemblies herein embrace the full scope ofthe aforementioned definition.

The exemplary system has been described with a degree of particularity.It is the intent, however, the invention include all modifications andalternations from the disclosed design falling within the spirit orscope of the appended claims.

The invention claimed is:
 1. Apparatus for applying a decorative film totwo or more surfaces of an elongated component which can then be cut andassembled to form part of a window or door comprising: a) multipledecorative film application stations for applying a decorative film todifferent surfaces of the elongated component, each decorative filmapplication station comprising: i) a support for the elongated componenthaving an input and an output side that supports the elongated componentas said elongated component moves through the decorative filmapplication station; ii) a drive for moving successive elongatedcomponents along a travel path through the application station from theinput side to the output side as the decorative film is applied to asurface of said elongated component, and iii) a heat and pressure rollerfor applying heat and pressure to the decorative film as the elongatedcomponent moves through the application station; and b) a controller incommunication with each of the multiple decorative application stationscomprising an executable program for resenting a menu of differentelongated components having different profiles and responding to a userselection of a particular elongated component by controlling movement ofheat and pressure roller at each application station to position theheat and pressure roller at each of the multiple decorative filmapplication stations to apply film to an appropriate surface of theelongated component.
 2. The apparatus of claim 1 wherein the support ateach of the multiple film application stations comprises a removablebacking fixture and wherein the controller responds to user selection ofa particular elongated component by identifying for the user: i) aproper choice for the heat and pressure roller for the selectedelongated component at each film application station, and ii) a properbacking fixture for supporting the selected elongated component as theselected elongated component moves through the multiple film applicationstations.
 3. The apparatus of claim 1 wherein based on the selection ofa particular elongated component, for each decorative film applicationstation, the controller determines: i) an angle of approach for contactbetween the elongated component and the heat and pressure roller, ii) aradial position of the heat and pressure roller with respect to anapplication surface of the elongated component during movement of theelongated component through an application station, iii) a target speedof movement of the elongated component through the film applicationstation, iv) a target temperature for the heat and pressure roller, andv) a width film for application at the film application station.
 4. Theapparatus of claim 1 wherein at least one application station comprisesa carriage which supports the heat and pressure roller for rotationabout a travel path of the elongated component through the at least onestation to change an angle of approach of the heat and pressure rollerwith respect to a surface of the component and a motor coupled to thecontroller for automated set up of the angle of approach of the heat andpressure roller.
 5. The apparatus of claim 1 additionally comprising amotor coupled to the heat and pressure roller that responds to thecontroller to position the heat and pressure roller with respect to thepath of component travel through the station.
 6. The apparatus of claim1 at least one film application station additionally comprises: a) adispensing roll for dispensing the decorative film through a region ofcontact with the component and a take up roll for coiling a film backingonce a decorative layer of the film has been applied to the component;and b) a heater for heating an outer, pressure applying surface of theheat and pressure roll which contacts the film in a region the filmengages the elongated component.
 7. The apparatus of claim 6 whereinsaid at least one film application station comprises a first carriagewhich supports the heat and pressure roll and a second carriage formounting at least one of the dispensing and take up roll and wherein thefirst and second carriages are relatively rotatable about the travelpath of the elongated component with respect to each other.
 8. Theapparatus of claim 6 additionally comprising a temperature sensorcoupled to the controller for monitoring temperature of the heat andpressure roll of at least one film application station and automaticallyadjusting the temperature by controlling activation of the heater. 9.The apparatus of claim 7 additionally comprising a brake for fixing anorientation of the first carriage with respect to the component travelpath.
 10. The apparatus of claim 1 wherein the heat and pressure rollerof at least one film application station is mounted for in and outmovement with respect to the elongated component and additionallycomprising a motor coupled to the controller for automatically adjustinga radial position of the heat and pressure roller with respect to theelongated component.
 11. The apparatus of claim 10 wherein the motor isa servo motor coupled to the controller for automatically adjusting theposition of the heat and pressure roller.
 12. The apparatus of claim 1wherein the controller presents a user interface on a screen forselecting different elongated components from a menu of such elongatedcomponents and further wherein the controller configures each of themultiple film application stations to apply a decorative film to adifferent surface of the elongated component at each station.
 13. Theapparatus of claim 10 wherein the controller includes a memory forstoring a recipe for multiple elongated component shapes wherein thecontroller positions the heat and pressure roller at different positionswith respect to a component path of travel at the respective stations.14. The apparatus of claim 1 wherein each of the multiple stationsincludes an optical sensor for sensing movement of the elongatedcomponent and initiating movement of the heat and pressure roller basedon sensing of the movement.
 15. The apparatus of claim 1 wherein eachfilm application station comprises a frame and additionally comprising acarriage mounted to the frame for rotation about an axis that isgenerally parallel to the component travel path and further wherein theheat and pressure roller is mounted to the carriage for rotation withsaid carriage to enable the head heat and pressure roller to approachdifferent surfaces of said elongated component oriented at differentangles with respect to the travel path.
 16. The apparatus of claim 14additionally comprising a drive for moving the heat and pressure rollerradially in and out with respect to a component travel path. 17.Apparatus for applying a decorative material film to two or moresurfaces of a component which can then be cut and assembled to form partof a window or door comprising: a) multiple application stations forapplying a decorative film to different surfaces of the component, eachapplication station comprising: i) a support for the component having aninput and an output side; ii) a drive for moving successive componentsalong a travel path through the application station from the input sideto the output side as the film is applied to a surface of saidcomponent, and iii) a transfer head for applying heat and pressure tothe film as the component moves through each application station fromthe input side to the output side; and b) a controller in communicationwith each of the multiple decorative application stations comprising anexecutable program for determining set up parameters for said transferhead at each application station including a position and an orientationof the transfer head to treat appropriate surface of the component withfilm at each of the multiple application stations; wherein the transferhead at each application station is mounted for radial in and outmovement with respect to the component and additionally comprising amotor coupled to the controller for automatically adjusting a radialposition of the transfer head with respect to the component.
 18. Theapparatus of claim 17 wherein the motor is a servo motor coupled to thecontroller for automatically adjusting the position of the transferhead.
 19. The apparatus of claim 17 wherein the controller includes amemory for storing a recipe for multiple component shapes wherein thecontroller positions the transfer head at different positions withrespect to a component path of travel at the respective stations. 20.Apparatus for applying a decorative film to two or more surfaces of acomponent which can then be cut and assembled to form part of a windowor door comprising: a) multiple application stations for applying adecorative film to different surfaces of the component, each applicationstation comprising: i) a support for the component having an input andan output side; ii) a drive for moving successive components along atravel path through the application station from the input side to theoutput side as the decorative film is applied to a surface of saidcomponent, and iii) a transfer head for applying heat and pressure tothe decorative film as the component moves through each applicationstation from the input side to the output side; and b) a controller incommunication with each of the multiple decorative application stationscomprising an executable program for controlling set up of said transferhead at each application station to position and orient the transferhead to treat an appropriate surface of the component with foil at eachof the multiple application stations; wherein the transfer headcomprises a heat and pressure roller and the support comprises aremovable backing fixture and wherein the controller presents a menu ofdifferent components having different profiles for decorative filmtreatment and responds to user selection of a particular component byidentifying for the user one or more of the following componenttreatment parameters: i) a proper choice for the heat and pressureroller at each application station, ii) a proper backing fixture for thecomponent as the component moves through an application station, iii) anangle of approach for contact between the component and the transferhead, iv) a radial position of the transfer head with respect to anapplication surface of the component during movement of the componentthrough an application station, v) a target speed of movement of thecomponent through the application station, vi) a target temperature forthe roller, and vii) a decorative film width for application at each ofthe multiple application stations.